Neopost PF-55 User manual

PF-55
FOLDER
USER’S GUIDE
Rev 3/08

TABLE OF CONTENTS
SUBJECT
PAGE
DESCRIPTION
1
SPECIFICATIONS
1
UNPACKING
1
SETUP
2
CONTROL PANEL
2
OPERATION
3
SETTING CUSTOM FOLDS
4
BATCH COUNTING
4
MULTI-SHEET FEEDING (OPTIONAL)
5
CROSS FOLDING
6
STACKER WHEEL POSITIONING CHART
6
STACKER WHEEL SETUP FOR THICK PAPER
7
OPERATOR MAINTENANCE
8
TROUBLE-SHOOTING
9

DESCRIPTION
1
Upper Fold Plate
Telescoping
Outfeed Stacker
Self Centering Paper
Side Guides
Infeed Tray
Infeed Tray
Extension
Infeed Tray
Lever
Lower Fold Plate
Non-Operator Side
Operator Side
Lower Fold Plate
FUNCTION
The PF 55 Folder is designed to perform a wide variety of folds using a variety of paper weights. The fold
plates are manually adjusted for standard folds and custom folds. Batch counting, self-centering side guides,
and the capability to cross-fold are added features. The folder will automatically stop after the last document
has been folded.
SPECIFICATIONS
Paper size:
3.5” X 5” TO 11” X 17” (88.9 W x 127 L TO 311W x 432 L mm)
Fold types:
Letter , Zig-Zag , Single , Gate , Fold Out ,
Double Parallel and Custom Folds
Feed table capacity:
Up to 500 sheets of 20# paper
Processing speed:
Up to 12,000/hour, depending on fold type.
Power requirements:
120 volts A.C., 50/60 Hz, 2.5 amps.
Dimensions during use:
Closed: 33” L x 20” W x 19” H (84 L x 51 W x 48 H cm)
Fully Extended: 60”L x 20” W x 19” H. (152 L x 51 W x 48 H cm)
Weight:
67 lbs (30.39 kg)
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Double Parallel and Custom Folds
Double Parallel and Custom Folds
Double Parallel and Custom Folds
Double Parallel and Custom Folds
Double Parallel and Custom Folds
1. Check package for shipping damage. If there is shipping damage, do not discard the box.
2. Remove the machine and packed components from the box. The fold plates, telescoping stacker, power
cord and cross-fold guide are wrapped separately in the box.
NOTE:
Two people must lift the machine from the box.
3. Place the machine on a solid stand.
4. Attach telescoping outfeed stacker.
UNPACKING

SETUP
1. Install upper and lower fold plates in position. Be sure
the plates are set fi rmly on the locating pins (Fig 1a
& 1b).
Slide the fold plate in until it meets the fi rst
locating pin then push down to lock it in position
(Fig. 2).
2. Make sure the power switch is in the “OFF” position.
3. Plug the power cord into the power inlet and the wall
outlet.
No
.
NAME
FUNCTION
1
Power Indicator
Lights up when power is on.
2
Start Button
Press to run the machine. Will not operate if a red fault light is on.
3
Stop Button
Press to stop the machine.
4
Test Button
Test folds one document.
5
Fault Indicator Lights
Stops the operation and indicates the problem area. Turn off the light by closing
cover, and/or placing paper on the in-feed tray. Press the “Reset” button to turn off
the “Fault detect” light.
6
Batch Counting Button
Select the batch counting function.
7
“-“ and “+” buttons
Select the number of documents to be folded.
8
Reset Button
Resets the fault detect circuit and the counter.
CAUTION:
when a fault happens and light is lit, only press the button one time. If
you press it a second time, you will reset the counter.
9
Counter Display
Shows the number of documents processed. When power is turned on it displays
“F-01”.
Fig. 1a
Locating Pins
Locating Pins
Fig. 1b
Locating Pins
Locating Pins
Locating Pins
Locating Pins
CONTROL PANEL
2
Fig. 2
Upper Fold Plate Pins
Lower Fold Plate Pins
1
7
2
3
4
5
9
8
6

OPERATION
1. Place power switch in the “ON” position.
2. To set the fold plate stop position, squeeze the stop
plate lever and move the stop plate to the desired
location on the upper and lower fold plates (Fig
3). Align the pointed part of the stop plate with the
desired marks on the decal and release the lever.
Fine adjustments can be made with the adjustment
knob at the end of the plate (Fig 4).
NOTE:
When doing a “Single” fold, be sure to move the
lower fold plate stop all the way to the front of the plate.
The plate must be fi rmly reinstalled on the locating
pins.
3. Extend the catch tray as required.
4. Move the stacker wheels to the proper position for
the paper size (Fig 5) ( Refer to chart on page 6).
5. Lift the in-feed tray extension into position.
6. Raise the in-feed tray lever.
7. Set the paper side guides for the paper you’re
using and lock in position.
8. Neatly stack paper on the in-feed tray.
9. Lower the in-feed tray lever.
10. Press the “Test” button on the control panel to
check the folds. Adjust as needed.
11. If the fold is skewed use the skew adjustment knob
to make corrections (Fig. 6).
12. When you’re satisfi ed with the test folds, press the
“Start” button to operate the machine.
Fig. 3
Fig. 6
Fig. 5
Fig. 4
3
Stacker Wheels
Stacker Wheel Positions A, B & C
Skew Adjuster
Skew Adjuster

SETTING CUSTOM FOLDS
BATCH
COUNTING
The batch counter can be set from “0” to “999”. Press the “Batch Counting” button to illuminate the “Batch
Counting” light. Press the “-“ or “+” buttons to select the number of documents to be folded. Press the “Start”
button. When the counter gets to “0” the machine will stop.
NOTE
: The batch counting program will remain on after turning the power off. You
must
press the Batch
must press the Batch must
Counting button to turn off the light and cancel the batch count setting.
Example 1: Uneven “Z”
1.
Measure the length of panel “A”
2.
Adjust the upper fold plate so that the stop plate lines
up with the measurements of the panel “A” i.e. if panel
“A” is 5 1/4” long slide the stop plate up or down so that it
lines up with the 5 1/4” mark on the fold plate.
3.
Measure the length of panel “B”
4.
Adjust the lower fold plate so that the stop plate lines
up with the measurement of panel “B”
5.
Load forms and press test. If folds are too long or too
short adjust accordingly.
1.
Measure the length of panel “A” & “B”
2.
Adjust the upper fold plate so that the stop plate lines
up with the measurements of panel “A” & “B”. i.e. if panel
“A” & “B” are 10 1/2” long slide the stop plate up or down
so that it lines up with the 10 1/2” mark on the fold plate.
3.
Measure the length of panel “B”
4.
Adjust the lower fold plate so that the stop plate lines
up with the measurement of panel “B
5.
Load forms and press test. If folds are too long or too
short adjust accordingly.
Example 2: Uneven “C”
4
Panel A
Panel B
Panel A
Panel B

5
MULTI-SHEET FEEDING (OPTIONAL)
MULTI-SHEET FEEDING (OPTIONAL)
The multi-sheet feeder is designed to fold pre-collated stapled or unstapled sets of paper of up to three 20 #
sheets of paper.
1. Make sure that all paper is removed form the feed
table.
2. Adjust the side guides on the feeder for the proper
paper size. Loosen the brass thumb screw, open
or close the guides to fi t the paper width and
retighten the thumbscrew (Fig 7a).
3. Slide the pre-collated paper set into the multi-sheet
feeder. When feeding stapled sets the documents
should be placed with the staple on the operators
side and leading (Fig 8).
4. The sheets of paper will be automatically pulled into
the folder (there is a one second delay after the
paper is placed in the feeder).
5. If the fold is skewed, turn the skew adjustment knob
located on the back of the feeder left or right to make
corrections (Fig 7b).
6. To remove the multi-sheet feeder depress the release
levers located on either side of the lower back side of
the feeder (Fig. 9), tilt the feeder forward and lift. To
reinstall depress the levers and reinsert.
Staple
Fig. 8
Fig. 7a
Fig 7b
Brass thumbscrew
Skew Adjuster
Release Levers
Fig. 9

STACKER WHEEL POSITIONING CHART
8.5" x 11" 8.5" x 14" 11" x 17"
Letter
Zig-Zag
Single
Gate
Fold Out
Double ll
A
A
B
A
B
A
A or B
A or B
B
B
C
A
B
B
C
C
C
A or B
Move the stacker wheel to the proper position indicated on the chart based on the fold and paper size.
6
CROSS FOLDING
Cross folding refers to folding a document in one pass and then running it through the folder a second time to
be folded again
.
Common Application: Folding a 11” x 17” document in half and then letter folding it to fi t in a standard #10
envelope.
1. Load folded paper into the feed tray with the fold
crease facing the non-operator side of the folder
(Fig 10).
Note: For best results fi rmly run your hand over the
fold crease to help fl atten the paper before loading.
2. Attach the cross fold paper guide onto the feed tray
paper guide (Fig. 11) and lower guide.
Note: Cross folding ability will vary based on the paper
weight and type. If the paper is to heavy it may not be
able to be cross folded.
Tab “B”
Tab “A”
Slot “B”
Slot “A”
Fig. 11
To install cross fold guide hook tab “A” into slot “A”
and then lower tab “B” into slot “B”
Fig. 10
Fold Crease
Cross Fold Guide

Thicker paper from 28 # up to 65 # may require special stacker wheel setup moving the stacker wheels closer
than the position “A” slot.
If stacking is inconsistent move the stacker wheels from the standard position #1 (Fig. 12) to the thick paper
weight position #2 (Fig. 13) as indicated in the pictures below. Position # 2 may also be good for small folded
documents.
Fig. 12 - Standard Stacker Wheel Position
Fig. 13 - Thick Paper Weight Position
Position 1
Position 2
7
STACKER
WHEEL SETUP FOR
THICK PAPER

OPERATOR MAINTENANCE
1. It is recommended to let forms cool for one-half hour, from the laser printer, before folding. This allows
toner to set on the forms and static electricity to discharge. The FD 400 Jogger is recommended for best
results. The Jogger squares the forms and dissipates heat and static created by laser printers.
2. Clean in-feed tires and fold rollers with Formax recommended roller cleaner & rejuvenator to remove paper
dust and toner. A Formax Cleaner Kit is available from your dealer. A damp cloth with water is the best
alternative.
CAUTION:
Do not use any chemicals other than the roller cleaner & rejuvenator or water.
CLEANING PROCEDUERS:
Fig. 14
Fold Rollers
1. Make sure machine is turned off and unplugged. All
folders have four (4) rubber rollers (Fig. 14).
2. Remove the upper and lower fold plates .
3. Using Formax roller cleaner, spray a new cotton cloth
until the cloth is saturated. Wipe the wet cloth in a
back and forth motion making sure to clean the entire
surface of the fold and seal rollers. Now take a dry
cloth and wipe off excess toner. The cloth should be
covered with black toner surplus from cleaning the
rollers.
4. Make sure to run 10-15 sheets of blank copy paper
to ensure all cleaner has been removed from the fold
rollers. Running blank sheets will remove any excess
residue of cleaner on the rollers.
8

TROUBLE-SHOOTING
TROUBLE
POSSIBLE CAUSE
REMEDY
Control panel lights are
not illuminated.
No power at the wall outlet.
No power to the machine inlet.
No power to the control panel.
Internal electrical failure
Check wall outlet.
Check power cord for frayed/broken
wires.
Press the button on the circuit breaker.
Call for service
“Cover Open” light is on.
Cover open
Magnetic switch is broken.
Close cover
Call for service
“Paper out “ light is on.
In-feed tray is empty.
Place documents on the in-feed tray.
“Fault detect” light is on.
Paper misfeed
Paper jammed at exit of folder.
Reload paper and press “Reset”.
Remove paper and press “Reset”.
Black marks on the folded
paper.
In-feed tires, separator, and/or
fold rollers are dirty.
Clean the parts with approved roller
cleaner and rejuvenator.
Fold is skewed.
In-feed tray is out of
adjustment.
Turn skew adjuster knob to remove the
skew.
Stacker belts do not turn.
Broken drive belt, worn drive
gear.
Call for service
Documents are wrinkled
or crunched.
Fold plates are not inserted
correctly.
Piece of paper or other material
is stuck in the fold plate.
Remove and reinstall fold plates. Be
sure they’re properly positioned.
Remove object from the fold plate.
In-feed tray lever does
not work
Broken spring
Call for service
Double feeding forms
Documents stuck together
Feed tire or separator worn
Jog forms to remove static electricity.
Call for service
Not feeding documents
Feed tire dirty
Feed tire or separator worn
Clean feed tire
Call for Service
9